Aqueous composition comprising multi-stage latex polymer particles

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Solution Overview

Problem

Aqueous compositions containing latex polymer particles used as binders for textiles face challenges due to the generation of formaldehyde as a byproduct during self-crosslinking, which is undesirable for both manufacturers and consumers.

Innovation Solution

The development of multi-stage latex polymer particles, where a first-stage polymer containing n-methylol functional monomers is bound to a second-stage polymer with formaldehyde-scavenging monomers, reducing formaldehyde content and enhancing mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If n-methylol functional monomers are used for self-crosslinking to enhance mechanical properties, then the mechanical properties of the textile-coated article are improved, but formaldehyde is generated as a harmful byproduct

Engineering Contradiction:

Improvemechanical propertiesVSAvoidformaldehyde generation

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent incorporates a formaldehyde-scavenging monomer into the polymer composition that reacts with and converts the harmful formaldehyde byproduct into harmless substances, thereby eliminating the harmful effect while preserving the beneficial self-crosslinking mechanism and mechanical property enhancement

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent creates a composite polymer system combining n-methylol functional monomer units (providing self-crosslinking and mechanical strength) with formaldehyde-scavenging monomer units (providing formaldehyde elimination), forming a multi-functional material that simultaneously achieves both objectives

Inventive Principle:

Principle #40Composite materials

2Device complexity

If traditional single-stage latex polymer particles are used, then the formulation is simple, but they generate unacceptable levels of formaldehyde

Engineering Contradiction:

Improveformulation simplicityVSAvoidformaldehyde content

Core Design Contradiction:

Device complexityVSObject-generated harmful factors

Solution Approach 1:

The patent divides the polymer particle formation into multiple stages, with different monomers incorporated at different stages, allowing the first stage to provide structural backbone and the second stage to introduce formaldehyde-scavenging functionality, thereby reducing formaldehyde while maintaining manageable formulation complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates polymer particles with non-uniform monomer distribution where formaldehyde-scavenging monomers are strategically incorporated to specifically address formaldehyde generation at the locations where n-methylol functional monomers undergo self-crosslinking

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach effectively minimizes formaldehyde levels while maintaining or improving the mechanical properties of textile-coated articles, making them suitable for applications exposed to water and other challenging conditions.

Implementation Method 1

a second-stage polymer containing (i) a formaldehyde-scavenging monomer

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS12139631B2Aqueous composition comprising multi-stage latex polymer particles

Publication Date: 2024.11.12 ROHM & HAAS CO

AI summary

The present disclosure provides an aqueous composition. The aqueous composition includes multi-stage latex polymer particles. The multi-stage latex polymer particles include (A) a first-stage polymer containing (i) an n-methylol functional monomer and (ii) a first vinyl monomer; and (B) a second-stage polymer containing (i) a formaldehyde-scavenging monomer and (ii) a second vinyl monomer. The first-stage polymer is bound to the second-stage polymer.